Dry Aerosol Impaction of Mesoporous Silica Aerogels

Aerogels are among the best known thermally insulating materials due their high porosities (>90%). This, in conjunction with their high transparency make them ideal candidates for highly insulating window coatings. However, current state of the art techniques involve time-consuming drying steps and poor mechanical robustness, severely limiting their wide-scale adaptation. By using a dry aerosol impaction process, synthesizing nanoparticles in a plasma, upstream of a slit-shaped nozzle and impacting these particles onto a substrate below, a novel way for producing mesoporous silica aerogels is shown. This removes the need for solution-based processing, improving the potential for high throughput. Thick (~100um), 90% mesoporous silica has been characterized showing low effective thermal conductivity (~0.02 W/mK) and high transparency (>90%). The morphology of these coatings were analyzed showing tight pore distributions. Film adhesion and stress have shown themselves to be major hurdles during the development of these coatings and will be the focus of future work.